Ford Fiesta
Ford Fiesta
Ford Fiesta
The all-new Ford Fiesta is the first small car segment application of the
companys kinetic design philosophy first introduced with the iosis and iosis X
concept cars and builds on the premium feel of latest production models like the
new Mondeo and Focus. Each new Ford has been created in a new
interpretation of this form language, translating the trademark bold graphic
elements and proportions to create a family of distinctive models. The result is
a new Fiesta that joins a family of vehicles immediately identifiable as new
generation Fords, yet with distinctive character to appeal to their target
audiences.
All-new Fiesta asserts its own air of confidence, stylishness and individuality.
Contents
Overview
Body
16
41
This self-study programme highlights the design and function of new vehicle models,
new automotive components or new technologies.
The self-study programme is not a repair manual!
All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.
REFERENCE!
Copyright 2009 Ford Motor Company of Southern Africa.
NOTE!
Overview
Kinetic Design
Energy in Motion
The new Fiesta marks a new era in Ford design, a step into the future. The
Fiesta embodies the spirit of Fords new Kinetic Design movement, which
translates into energy in motion. It is bold and independent. It is distinctive and
emotional. It is athletic and muscular. Even when standing still it looks poised,
ready to strike at any moment. The new Fiesta is also the first major product of
Fords global product revitalisation strategy process.
Foxy Eyes
The bold new cat-eye headlamps add even more visual intrigue. It invites you
closer, hinting at a stirring personality behind those daring eyes. It is sexy, sultry
and captivating.
The Shout
The large sporty front grille proudly announces the strong new face of Ford. It is
constantly shouting and proclaiming your existence boldly to the world.
Perfected to suit a lifestyle that demands both fashion and practicality. Why
whisper when you can shout?
Ready to Pounce
The Fiesta imparts a highly dynamic stance and controlled tension. Every line
conveys a sense of agile muscularity, the look of energy in motion.
The Silver Lining
A touch of class is added with the silver character line which accentuates the
higher belt-line and window profile. A simple expression that underlines your
presence.
4
Overview
1.4 Sigma & 1.6 Ti-VCT Engine
1.6TDCi Engine
ENGINE
1.4
1.6
1.6 TDCi
Types
1.4L
1.6L
1.6L
Capacity (cc)
1388
1596
1560
76 x 76.5
79 x 81.4
75 x 88.3
Compression Ratio
11.0 : 1
11.0 : 1
18.0 : 1
71 @ 5750
88 @ 6000
66 @ 4000
125 @ 4500
149 @ 4250
200 @ 1500
CO2 emissions
138
139
110
Fuel system
Multipoint injection
Multipoint injection
Overview
Fiesta Ambiente
1.4l, 1.6l and 1.6TDCi Engine
5-door Hatch
5-speed iB5 Manual Transmission
Overview
The new Ford Fiesta is the car for now.
A revolutionary style icon; it redefines what a small hatch should be. The New
Fiesta demonstrates that small cars can be styling and sophisticated and yet
stay true to Fiesta's traditional strengths of practicality, value for money, agility
and safety.
Key Features
Dual Airbags
Standard Air conditioner with pollen filter
Twin chamber Halogen Reflector headlights
Manual central locking
Cap less fuel filler neck with misfuel inhibit (petrol and diesel)
Fiesta Trend
1.4l and 1.6l
5-door Hatch
5-speed iB5 Manual Transmission
Overview
Confident Driving
The real beauty of the new Fiesta is that it is as easy to maintain as it is to drive.
Engineered and built in Germany you experience the build quality, attention to
detail and innate reliability every time you get behind the wheel. The new Fiesta
offers great fuel economy which means more money in your wallet, and that
means less to worry about at the end of the day.
Key Features
Overview
Fiesta Titanium
1.4l and 1.6l
5-door Hatch & 3-door hatch
5-speed iB5 Manual Transmission
Overview
The Choice is Yours
The new Fiesta is available in 3 door and 5 door body styles, powered by the
refined and improved 1.6 turbo diesel, 1.4 petrol engine and a new 1.6 petrol
engine. Both petrol engines were engineered to offer great power and fuel
efficiency and still be environmentally friendly. All engines feature a new slick 5speed gearbox. So whether you prefer a torquey diesel engine or an
enthusiastic petrol engine, theres a Fiesta for you.
Key Features
Technical Specifications
Dimensions
2489mm
3950mm
1428mm
1474mm
1973mm
Technical Specifications
New Technical features
Chassis
Front axle: McPherson struts
Rear axle: Twist-beam axle
Electric power steering
Fuel System
Cap less fuel tank filler pipe
Electrics
Air conditioning (manual or with EATC (Electronic Automatic Temperature
Control))
Central module configuration
Audio system with separate multifunction display and advanced menu
navigation
Body
Two body versions (3-door and 5-door)
A- and B-pillar reinforcement made from ultra high-strength boron steel
Power windows with pinch protection (driver side only)
The DLC is located beneath the light switch behind the instrument panel. The
DLC can be accessed by opening the storage compartment on the driver side.
Technical Specifications
Front Suspension
General
A newly developed McPherson front suspension with L-shaped lower arms is
used. The lower arm bushes have been enlarged compared with the previous
model. This further improves front axle rigidity. The shock absorbers are gas
shock absorbers.
5 Subframe
2 Stabilizer bar
6 Lower arm
3 Suspension unit
Rear Suspension
General
Characteristics of rear axle:
Twist-beam axle (torsionally rigid axle)
Single-pipe gas shock absorbers with stable damping performance for
optimum handling
Axle suspension uses large rubber bushes for optimum ride comfort.
Function
If compression takes place on both wheels evenly (for example when a load is
placed on the vehicle), the whole axle unit swivels evenly in the rubber-metal
bearings. If only one wheel is compressed, the cross-beam twists (undergoes
torsion) and acts as a stabilizer.
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Technical Specifications
1 Shock absorber
2 Spring
The ABS sensor rings are built into the seals in the front wheel bearings. The
wheel sensors are joined to the main wiring harness using a separate
connecting cable.
11
Technical Specifications
Power Steering
1 Steering gear
2 Steering column
7 Joint shaft
3 Steering shaft
9 Tyre-rod
Universal joint
General
This vehicle employs electric power steering.
The electric power steering is integrated into the steering column.
As soon as the steering wheel is moved, an electric motor (electric power
steering motor) assists the steering movement. The rotary motion of the motor
is transferred directly to the steering shaft using a worm gear.
The hydraulic power steering pump is therefore no longer required.
Advantage: The electric power steering is only active when a steering
movement occurs. This decreases the load on the engine and therefore
reduces the fuel consumption.
The electric power steering consists of the following main components:
Electric power steering motor,
Reduction gear,
Steering torque sensor,
PSC module.
12
Technical Specifications
Overview of operation
When a steering movement occurs, it is detected by the steering torque sensor.
The signal from the steering torque sensor is used by the module to calculate
the power of the steering assistance.
The module drives the motor with the corresponding current.
The rotary movement of the motor is transferred directly to the steering shaft
through a worm wheel.
A Joint shaft
D Steering column
B Reduction gearset
E PSC module
13
Technical Specifications
Fuel System
Capless fuel tank filler pipe
NOTE: The locking unit in the fuel tank filler pipe is available as an
individual spare part.
The conventional fuel tank filler cap is dispensed with for this vehicle.
A spring-loaded locking flap closes off the upper end of the fuel tank filler pipe in
place of the filler cap.
The fuel tank closing flap underneath seals off the fuel system to the outside.
In its rest state, the locking flap lies on a flange worked into the fuel pump
nozzle guide (cannot be seen in the illustration).
When the fuel pump nozzle is introduced, the locking pin is pushed downwards.
The fuel pump nozzle guide is now pressed against the compression spring
force by the shape of the fuel pump nozzle.
The action of pressing away the fuel pump nozzle guide in the direction of the
compression spring releases the locking flap and the fuel pump nozzle is
admitted.
The diameter of the fuel pump nozzle is decisive here. The fuel pump nozzle
guide is constructed in such a way that only a fuel pump nozzle of the correct
size can release the locking mechanism.
As the fuel pump nozzle is introduced further, the spring-loaded tank closing
flap is opened.
Advantage:
Incorrect refuelling of diesel vehicles with the fuel-pump nozzle at the service
station (petrol instead of diesel) is no longer possible.
There is no dirtying of the hands from screwing off the fuel tank filler cap.
Instructions on refuelling from a reserve fuel can:
There is a funnel in the vehicle for refuelling from a reserve fuel can (applies to
both diesel and petrol vehicles).
The diameter of the funnel is matched to the type of engine in the vehicle
(diesel or petrol).
NOTE: Always insert the funnel until it reaches the stop. Otherwise there
is the danger that the tank closing flap may not be fully open.
14
Technical Specifications
NOTE: The locking unit in the fuel tank filler pipe is available as an
individual spare part.
1 Compression spring
4 Locking pin
Locking flap
15
Body
Jacking and Lifting
WARNING: Always position the vehicle on a hard level surface. If the
vehicle must be jacked up on a soft surface use load spreading blocks
under the jack. Always chock the wheel diagonally opposite the jacking
point. Failure to follow these instructions may result in personal injury.
NOTE: When using the vehicle jack, refer to the owner guide for correct
operating instructions.
16
Body
Body Construction
General
Two design principles have prevailed in body design. The body design can
either be an integral body-frame or a frame with all attached superstructures.
Mixed versions are also possible, with the design significantly increasing the
stability of the frame. In all versions, the passenger cell must be preserved in
the event of an accident. To this end, the front and rear ends are designed so
that they absorb the energy of the impact via crumple zones.
The use of modern design and manufacturing methods, and the use of body
panels whose reshaping and strength properties have been finely balanced,
mean that despite the requirements can be met.
Integral body-frame
The integral body-frame is completed with ancillary components, such as doors,
hood, bumpers and other components. The advantages of this are:
The safety of the driver and passengers is paramount for every body design.
There are two key safety aspects in the body:
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Body
The safety body cell is characterized by the following design features:
Deformation behavior
Different materials and design features lead to staged deformation of the front
and rear of the vehicle in an accident. The passenger cell remains undamaged,
and the driver and passenger are not shut in.
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Body
A- and B-Pillar Reinforcement
The A- and B-pillar reinforcement is made of the highest strength boron steel.
These sheet metal parts can only be replaced as a complete unit during repairs
and that section repairs are not possible.
Special installation and removal requirements must be observed during repairs.
Special tools are also required. Relevant instructions are available in the current
service literature.
19
Body
Cut the top section of the panel 100mm below the inside of the door frame and
drill out the 43 spot wields.
Set the heat gun to 170 Degrees Celsius and apply heat to the lower section of
the panel to loosen the bonder. The outer panel can now be removed and the
section can cleaned and prepared.
20
Body
Cut the replacement panel to size to allow for butt joints. Apply bonder to the
lower section of the B-Pillar. Remember not to apply bonder in areas where
wielding takes place.
Fit the replacement panel and spot wield in the 43 designated areas.
21
Body
Join the panel at the joints with full seam wields using MIG welding equipment
and spot wield the lower section.
22
Body
Exterior Trim
Roof strip
Tailgate lettering
Windshield strip
10
Tailgate emblem
11
Trim strip-tailgate
12
Variant sign-tailgate
System Operation
Depending on the way in which they are attached, the components can either
be reused or need to be replaced.
Components which are attached with adhesive tape should be detached with a
plastic wedge.
Component Description
Windshield strip
Depending on the way in which they are attached, the components can either
be reused or need to be replaced.
Components which are attached with adhesive tape should be detached with a
plastic wedge.
23
Body
Windshield strip (continued)
Roof strip
24
Body
Trim strip-front door window (5-door)
25
Body
Trim strip-rear side window (5-door)
26
Body
Trim strip-rear side window (3-door)
27
Body
Rocker panel moulding (continued)
On each side the rocker panel moulding consists of:
-
The moulding is retained with clips, securing strips and adhesive tape.
The trim strip can be reused after it has been removed.
Tailgate lettering
Tailgate emblem
The lettering is retained with adhesive tape.
A new one will need to be fitted after the old one has been removed.
28
Body
Tailgate emblem (continued)
Trim strip-tailgate
29
Body
Tailgate variant sign
30
3 Side lamp
4 Low-beams
Body
Headlamps (continued)
The following types of headlamp are used:
Conventional headlamps with free-form reflectors and
Projector headlamps.
Conventional incandescent bulbs are fitted as the light source.
Incandescent bulbs for dipped and main beam:
Dipped beam: H7
Main beam: H1
Projector headlamps
Projector headlamps have the following advantages compared with
conventional headlamp systems:
Greater range and optimum radiance,
More even distribution of the light beam.
Side View
A
A
B
D
Removing
Remove the plug connector (D) from the rear of the headlamp.
Loosen and remove the 3x screws pictured A, B & C
Installing
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Body
Bumpers
1 Front bumper
4 Rear bumper
2 Fog lights
3 Air deflector
6 Cover, bumper
The bumpers are painted in the body colour as standard for all vehicle variants.
The replacements bumper cover is only available in grey.
A
B
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Body
Removing and Installing Front bumpers (continued)
Once headlamps have been removed loosen 4x Screws A and B on both sides
of the vehicle.
Loosen screws C and D as well.
For vehicles with parking aid.
Loosen clips A and B and lift coolant reservoir (C) out of its position.
Disconnect X2 plug connector.
Detach 5x cable ties from vehicle body.
B
A
33
Body
Removing and Installing Front bumpers (continued)
For all vehicles.
34
Body
Removing fog lamps (continued)
Two people will be needed to slide the bumper cover forward off the
alignment pins (A) and to release the retaining clip (B) at the bottom of the
bumper cover.
35
Body
Removing front bumper grills.
Lift the four retaining clips (A) on the upper grill and pull it out in the forward
direction.
A
A
Release the X18 retaining clips on the lower grill and pull it out in the forward
direction.
Installing
Installation is done in the reverse order.
36
Body
Removing and Installing Rear bumper
Remove rear mud flaps on both sides if equipped.
A
B
37
Body
For vehicles with parking aid:
B
A
B
B
A
B
38
Body
Two people will be needed to slide the bumper cover up and forward off the
alignment pins.
3-Door Model:
A 5mm drill bit will be needed to drill out the plastic wields A. Loosen 4X screws
B from rear fog lamp and unclip X12 plastic retaining clips to remove lower
bumper skin.
B
A
39
Body
5-Door Model:
Loosen 4X screws A from rear fog lamp and unclip X12 plastic retaining clips to
remove lower bumper skin.
Installing
Installation is done in the reverse order.
40
Restraint System
Supplemental Restraint System
Safety precautions when working on airbag
General:
41
Restraint System
Airbags
Following removal, airbag units must be stored with cushioned side facing
upwards.
Side airbag
42
It is NOT permissible to use seat covers or protective covers which have not
been approved for use on Ford seats with side airbags.
The backrest foam fill is not to be cut away in the area of the side airbag.
When installing, all new upholstery clips must be fitted in the same positions
as the original ones.
The backrest cover in the area of the side airbag is never to be repaired (on
account of special thread and precisely defined seam).
Always replace the backrest padding after the side airbags have been
triggered.
If side airbag units are renewed, remove sticker with airbag number from
new side airbag unit and stick it over old sticker on seat pan.
Never pierce cover in area of airbag and sensor mat with upholstery needle
or similar pointed objects.
Restraint System
Belt pretensioner in the retractor
43
Restraint System
Overview
General
Three different versions are available:
Version 1 comprises the following components:
Single-stage driver airbag,
Single-stage passenger airbag,
Driver and passenger belt pretension in the retractor,
Front crash sensor,
Driver and passenger safety belt buckle switch,
Passenger seat occupancy sensor,
RCM (restraint control module).
Version 2 comprises the following components:
1. Components of version 1,
2. Driver and passenger side airbag (upper body and head),
3. Driver and passenger crash sensor,
4. Knee airbag.
Version 3 comprises the following components:
Components of version 1,
Driver and passenger side airbag (upper body),
Driver and passenger crash sensor,
Knee airbag,
Driver and passenger head airbag.
44
Module number
Description
8V51-14B321-Ax
8V51-14B321-Bx
8V51-14B321-Cx
8V51-14B321-Ex
8V51-14B321-Fx
Restraint System
Component Location
10
11
12
Driver airbag
13
14
45
Restraint System
System operation and Component description
Control diagram
46
Driver airbag
10
11
12
13
Knee airbag
14
15
Restraint System
System Operation
When the ignition is switched on, the RCM performs a self-diagnostic.
All components of the safety system, apart from the driver and passenger safety
belt buckle switches and the seat occupancy sensor, are checked. If a fault is
detected, the airbag indicator light is activated for 8 seconds after the ignition is
switched on. The first 8 seconds of the ignition cycle always follow the same
pattern: on for the first 3.2 seconds, the off for 4.8 seconds. Only after these 8
seconds can the airbag indicator light be used as a fault indicator.
Triggering of the airbags and belt pretensioners is dependent on the impact
speed and the impact angle.
In the normal situation the signal to the PCM is linked to a triggering of airbags.
However, in the event of a side-on collision with Version 1 (no side airbags), the
signal is likewise sent to the PCM, even though no airbags have been triggered.
The same applies in the event of a collision from behind: no airbags triggered,
but a signal is sent to the PCM. Due to this signal the PCM interrupts the fuel
supply to the engine so that the engine switches off.
The RCM must be renewed after the airbag has been triggered. When the
RCM is replaced, the module must be configured with IDS (Integrated
Diagnostic System).
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Restraint System
Passenger side function
When the ignition is switched on, the module checks whether the passenger
seat is occupied by a person and whether this person is wearing a safety belt.
The seat occupancy sensor and the safety belt buckle switch pass this
information to the RCM.
If a road speed of approx. 25km/h has been reached and the passenger is not
wearing a safety belt, the safety belt warning lamp lights up and an audible
signal is sounded.
Component Description
Seat occupancy sensor
The seat belt occupancy sensor consists of several sensor cells and is
integrated into the foam structure of the passenger seat.
It recognizes whether a person is sitting in the passenger seat.
The sensor is used in vehicles which have a safety belt warning light.
It does not disable the passenger airbag.
The seat occupancy sensor is integrated into the seat cushion and is not
available as an individual part.
48
Restraint System
Belt pretensioner in the retractor
Electrical connector
Ignition unit
The belt pretensioner is integrated into the retractor and installed on the driver
and passenger sides.
On the outside of the safety belt retractor there is a metal tube, at the upper end
of which a pyrotechnic igniter is located. It is connected with the metal tube via
joining connector.
Side airbag
Two different side airbags are installed depending on the equipment version.
In vehicles without a head airbag, there is a side airbag which protects the area
of the upper body and head.
In vehicles with a head airbag, there is a side airbag which protects the area of
the upper body.
Knee airbag
The knee airbag is installed in the instrument panel, below the steering wheel.
In the event of a head-on collision, it protects the knee and leg area and
prevents the driver from slipping down under the safety belt.
49
Restraint System
PAD deactivator switch
50
Notes:
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